RECOVERY/RECYCLE/RECHARGEOperating Instructions CONTENTS SAFETY SUMMARY SAFETY INFORMATION ELECTRICAL SHOCK HAZARDS MOTION HAZARDS FUME HAZARDS HEAT/FREEZING HAZARDS EXPLOSION/FLAME HAZARDS ADDITIONAL SAFETY INFORMATION 4 4 4 4 4 5 5 5 INTRODUCTION CERTIFICATION ABOUT THIS MANUAL ABOUT YOUR RECOVERY/RECYCLE AIR CONDITIONING SERVICE CENTER WARRANTY GENERAL INFORMATION PRINCIPLES OF OPERATION SETUP THE MACHINE BASIC COMPONENTS CONTROLS AND CONTROL SYSTEM FUNCTION SELECTOR KEYBOARD ALARMS 5 6 6 6 6 6 7 7 8 8 9 9 9 PRELIMINARY OPERATIONS AUTOMATIC PROCEDURE ASSISTED PROCEDURE RECOVERY AND RECYCLING VACUUM ADDING NEW OIL CHARGING THE A/C SYSTEM 10 10 12 12 12 12 13 ROUTINE MAINTENANCE FILLING THE MACHINE TANK VACUUM PUMP Oil Fill Checking Oil Level Oil Change REPLACING THE DRYER FILTERS FILLING THE NEW OIL CONTAINER EMPTYING THE USED OIL CONTAINER CHECKING THE SCALE RESPONSE PURGING NON-CONDENSABLE GASES 14 14 15 15 16 16 16 17 17 17 17 SETTINGS LANGUAGE 18 18 UNITS OF MEASUREMENT WEIGHT PRESSURE TEMPERATURE 2 18 19 19 20 DATA PASSWORD PROTECTION 20 20 SYSTEM FLUSHING CUSTOMIZING THE DBA (DATABASE ADVANCED) DATA ENTRY USE DELETION DATABASE UPGRADE 21 21 22 22 22 22 ENGLISH CONVERSION CHART 22 3 . read. ELECTRICAL SHOCK HAZARDS • To reduce the risk of electric shock. When working near moving engine parts. The following safety alert symbols identify important safety messages in this manual. If extension cord must be used. Failure to comply with these instructions could result in personal injury and/or property damage. Turning off controls will not reduce this risk. or service this equipment. Use of an improper extension cord could result in a risk of fire. An extension cord should not be used unless absolutely necessary. Please read and retain these instructions for the continued safe use of your service system. make sure: a. operate. Keep hoses and tools clear of moving parts. AND DEATH! To reduce the risk of discomfort. That the wire size is large enough for the length of cord as specified below: Length of cord in feet: AWG size of cord: 25 16 50 12 100 10 150 8 MOTION HAZARDS • Engine parts that are in motion and unexpected movement of a vehicle can injure or kill. and service. and follow the following safety instructions. local industrial codes and local inspection requirements also provide a basis for equipment installation. make certain that anyone else that uses this equipment understands and follows these safety instructions as well. READ ALL SAFETY INFORMATION CAREFULLY before attempting to install. • Do not operate the machine with a damaged cord or plug — replace the cord or plug immediately.SAFETY SUMMARY The following safety information is provided as guidelines to help you operate your new system under the safest possible conditions. That extension cord is properly wired and in good electrical condition. or even death. and shape as those on plug on recycler. Never fill the tank to more than 80% of maximum capacity as this will not leave an expansion chamber for absorbing any pressure increases. • The unexpected movement of a vehicle can injure or kill. When working on vehicles always set the parking brake or block the wheels. 4 . read. unplug the power supply cord from the outlet before attempting any maintenance or cleaning. RETAIN THE FOLLOWING SAFETY INFORMATION FOR FUTURE REFERENCE. Occupational Safety and Health Act regulations. FUME HAZARDS • FUMES. In addition. wear snug fit clothing and keep hands and fingers away from moving parts. ILLNESS. The true craftsman also knows that tools are dangerous if misused or abused. electric shock and component damage. understand. AND VAPORS CAN CAUSE DISCOMFORT. and c. understand. They know that the tools represent years of constantly improved designs and developments. b. GASES. size. In addition. That pins on plug of extension cord are the same number. Published standards on safety are available and are listed at the end of this section under ADDITIONAL SAFETY INFORMATION. use. The following safety instructions are to provide the user with the information necessary for safe use and operation. illness. disconnect the power cord by pulling on the plug rather than the cord. To reduce risk of discomfort. SAFETY INFORMATION Every craftsman respects the tools with which they work. To reduce the risk of damage to electric plug and cord. The National Electrical Code. Always stay clear of moving engine parts. Any equipment that uses chemicals can be potentially dangerous to use when safety or safe handling instructions are not known or not followed. make certain that anyone that uses the equipment understands and follows these safety instructions as well. be alert to the possibility of personal injury and carefully read the message that follows. and follow the following safety instructions. illness. When you see one of the symbols shown here. Hoses and tools can be thrown through the air if not kept clear of moving engine parts. or death. org CAUTION: This equipment should be used in locations with mechanical ventilation that provides at least four air changes per hour or the equipment should be located at least 18 inches (457 mm) above the floor. We are dedicated to solving the issues surrounding the safe containment and proper management of refrigerants.www.obtainable from the American National Standards Institute. ANSI Standard Z87. CAUTION: Do not pressure test or leak test R134a service equipment and/or vehicle air conditioning systems with compressed air.ansi. seek immediate medical assistance. death can result. at the end of the working day or in between services (when services do not immediately follow). The manufacturer shall not be responsible for any additional costs associated with a product failure including. Alternate refrigerants may contain flammables such as butane or propane and can explode or cause a fire.” or the equivalent. Refrigerants are under pressure and can be forcibly sprayed in all directions if carelessly handled. Stop work and take necessary steps to improve ventilation in the work area. Refrigerants are under pressure and can be forcibly sprayed in all directions if carelessly handled.• Avoid breathing A/C refrigerant and lubricant vapor mist. DO NOT adapt your unit for a different refrigerant — system failure will result. loss of refrigerant. 5 . the lungs can be seriously damaged. refer to the following standards. • For general safety reasons. refrigerants become liquid. INTRODUCTION This machine is ETL Laboratories approved. Before recycling use proper equipment such as a refrigerant identifier. • Refrigerants can cause frostbite and severe burns to exposed skin. These mixtures. Additional health and safety information may be obtained from refrigerant manufacturers. or throat irritation as this indicates inadequate ventilation. Your new machine incorporates the latest technology and state of the art features to aid you in servicing R134a air conditioning and refrigeration systems. ATTENTION: Technicians using this equipment must be certified under EPA Section 609 (Environmental Protection Agency). state. they can freeze tissue very rapidly. loss of work time. cross contamination of refrigerant. • Refrigerants can also severely injure or cause permanent blindness to unprotected eyes.1 — SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION . and unauthorized shipping and/or labor charges. Avoid contact with refrigerants and always wear protective gloves and make certain other exposed skin is properly covered. Fax (212) 398-0023 . ADDITIONAL SAFETY INFORMATION For additional information concerning safety. If sufficient quantities are taken into the lungs. • Stop the recycling process if you develop momentary eye.. New York. Recovering alternate refrigerants will also void the warranty on your machine. 11 West 42nd St. ENGLISH HEAT/FREEZING HAZARDS • When under pressure. Used oil should be discarded per applicable federal. EXPLOSION/FLAME HAZARDS • Never recover anything other than the approved refrigerants as specified on the machine. DUE TO LEAKS. if necessary. WHICH WOULD INCREASE THE NCG LEVEL IN THE RECOVERED REFRIGERANT. WARNING: There is the possibility of refrigerant contamination in the refrigerant container or the mobile A/C system being serviced or refrigerant container. DURING THE RECOVERY PROCESS. use service equipment certified to meet the requirements of SAE J2788--R134a recycling equipment. NOTE: Use only new refrigerant oil to replace the amount removed during the recycling process. nose. Telephone (212) 642-4900. As they evaporate. may cause injury or property damage. IMPORTANT: R134a systems have special fittings (per SAE specifications) to avoid cross-contamination with R12 systems. and local requirements. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. When these gases are breathed in. Some mixtures of air and R134a have been shown to be combustible at elevated pressures. Avoid contact with refrigerants and always wear safety goggles. but not limited to. When accidentally released from the liquid state they evaporate and become gaseous. nose. PERIODICALLY INSPECT AND MAINTAIN REFRIGERANT HOSES AND SEALS TO ENSURE THAT HOSES AND SEALS PREVENT THE ADDITION OF EXCESS AIR. Never run an engine without proper ventilation for its exhaust. If you believe you have exposed your lungs to released refrigerant. if ignited. To remove R134a from the A/C system. in compliance with SAE J2788. Exposure may irritate eyes. NY 10036. see to it that all valves on hoses and the machine are closed. and throat. • Always perform vehicle service in a properly ventilated area. and unpacking.CERTIFICATION All technicians opening the refrigeration circuit in automotive air conditioning systems must now be certified in refrigerant recovery and recycling procedures to be in compliance with Section 609 of the Clean Air Act Amendments of 1990. Please take the time to study this manual before operating the machine. To activate the warranty. inept or improper use. GENERAL INFORMATION Height: 41. Other functions can also be performed with the electronic scale as you will discover during the operating procedures. paneling. or other accidental events. loading and unloading.7 inch Width: Machine identification information is printed on the data plate on the rear of the machine (see Figure 1). Before operating this machine for the first time. the machine inevitably produces noise. the Manufacturer reminds the Customer that according to international and national laws and regulations in force the goods are shipped at the sole risk of the latter and. The warranty consists of free-of-charge replacement or repair of defective component parts or parts considered defective by the Manufacturer. the Manufacturer’s original packing must always be used and scale must be locked prior to shipping. Reference to the machine serial number must be included in any requests for spare parts. Either standard or metric units of measure can be selected. or phenomena not inherent to normal use and operation of the product. OPERATION procedures. the average noise level of the machine is less than 70 dB (A). Overall machine dimensions: 19. repairs performed by unauthorized personnel and/or with non-original spare parts. ABOUT YOUR AIR CONDITIONING RECOVERY/RECYCLE SERVICE CENTER Your machine incorporates a highly accurate electronic scale for determining charging weights. If your new machine is not properly prepared to perform a service. The Manufacturer therefore declines any and all responsibility in merit of CLAIMS for damages due to shipping. NOTE: Regarding the above.5 inch Weight: 200 lb Like any equipment with moving parts. In order to avoid damage during shipping for repairs.7 inch Depth: 20. damage caused by shocks. and special provisions adopted by the Manufacturer are such that during work. your service data could be erroneous. WARRANTY This product is warranted against any defect in materials and/or construction for a period of 1 (one) year from the date of delivery. mail the attached warranty card. perform all PREPARATION FOR USE instructions. the goods are shipped uninsured. This warranty does not cover defects arising from normal wear. to operate within the objectives of the Montreal Protocol. follow all procedures in the order presented. for your Air Conditioning Service Center. ABOUT THIS MANUAL This manual includes a SAFETY SUMMARY. NOTE: The machine is intended for indoor use only. The construction system. use of unsuitable lubricants and/or tracer fluids. incorrect or improper installation. The manufacturer declines any and all responsibility for damage to vehicles on which recovery/recycling and recharging are performed if said damage is the result of unskillful handling by the operator or of failure to observe the basic safety rules set forth in the instruction manual. unless otherwise specified in the confirmation of order phase. Please pay close attention to the SAFETY SUMMARY and all WARNINGS and CAUTIONS provided throughout this manual. The product for which repair under guarantee is requested must be shipped to the manufacturer under the customer’s exclusive responsibility and at the customer’s exclusive expense and risk. MACHINE PREPARATION FOR USE. etc. For information on certification call MACS Worldwide at (215) 631-7020. In order to properly perform a complete air conditioning service. Then keep this manual close at hand for future reference. fires. 6 . use of improper maintenance procedures. Anyone intending to use the machine should become familiar with ALL the information included in this manual (especially the SAFETY SUMMARY) before attempting to use it. The warranty will expire automatically at the end of the twelve-month period or whenever one of the following occurs: failure to perform maintenance. refer to Setup on page 7. Your new machine has been designed specifically to use R134a. and MAINTENANCE instructions. remove the protection under the refrigerant scale as follows (UNLOCK SCALE): . .) .) NOTE: In the event that the equipment has to be transported. recycled and returned to the tank installed in the machine.Switch the machine on. 4-1) until the display signals ZERO Ref.Check that the screw (Fig. and also permits purging the A/C system of humidity and deposits contained in the oil. 4-1) is actually locked. Referring to Figure 4. mount the hose with the BLUE quick-connect coupling on the male threaded connector indicated by the BLUE LOW PRESSURE symbol and the hose with the RED quick-connect coupling on the male threaded connector indicated by the RED HIGH PRESSURE symbol. SETUP The machine is supplied fully assembled and tested. 3 � � � FIG.Loosen the nut (Fig 4-2.Use two 10mm wrenches. 4-1) two to four turns (do not remove from machine. 4 7 . The machine also permits running certain operational and leak tests on the A/C system. . 4-1). 4-2.Tighten the nut (Fig.Tighten the nut (Fig. The fluid is then filtered. the machine permits recovering and recycling refrigerant with no risk of release into the environment. if necessary repeat the locking operation from the beginning.) . the refrigerant tank scale MUST be locked in place as follows: .Loosen the screw (Fig. 4-2. . � � � � FIG.Tighten the screw slowly (Fig. Referring to Figure 3.ENGLISH ������ ������ PRINCIPLES OF OPERATION In a single series of operations. Available. 4-2) forcefully (using the second wrench to lock the screw (Fig. . The machine is equipped with a built-in evaporator/separator that removes oil and other impurities from the refrigerant recovered from the A/C system and collects them in a container for that purpose.) .Loosen the nut (Fig. 5 � FIG. 8 . 6. 6 � � � � � � � � � FIG. 7 and 8. 7 8 FIG.THE MACHINE BASIC COMPONENTS (Refer to Figures 5.) A) Control Console G) Vacuum Pump M) Used Oil Bottle B) Service Valves H) Wheels N) Drier Filters C) High & Low Service Ports I) Main Switch O) Tank D) New Oil Bottle E) Sight Glass F) Serial Port L) Electronic Scale J) Socket for Electrical K) Fuse Holder Supply Plug P) Tank Heater � � � � � � FIG. NOTE: Never transfer refrigerants to a cylinder or tank unless it is D. or end-of-operation state silences the audible alarm. Press to move upward from one procedure or operation to another within a menu. Press START to resume operation from the point of interruption. charge enough refrigerant into the D.8 kg. a beeper will sound and the LCD will display SERVICE ALARM. A1) High pressure gauge A3) Keyboard A2) Low pressure gauge A4) LCD: 4 lines. that is. when the total recovered amount of refrigerant reaches 114 lbs. a 9 EMPTY TANK ALARM: SERVICE ALARM: . To cancel this alarm. To clear the alarm. 9 FUNCTION SELECTOR KEYBOARD STOP: Press to interrupt the operation being performed -.vacuum/oil charging .) The RECOVERY operation is automatically interrupted. approved for refilling and only have a check valve in them that allows refrigerant to leave the tank. The procedure will be restarted from the beginning. Purging Non-Condensable Gases. Since these tanks have a check valve and DO NOT have pressure safety devices on them they cannot be refilled by 69788.recovery . D. Pressing STOP during an alarm state.O. NOTE: “Tank” and “Bottle” are both used to describe a refrigerant container.) If a refrigerant tank is overfilled. approval is indicated by the designation “DOT 4BA” or “DOT 4BW” stamped on a tank’s collar (handle. filters should be purchased to have ready when 69788 requires that the filters be replaced. it may explode! Failure to abide by these warnings may cause personal injury or death.O. tank so that the refrigerant available will be approximately 12 to 15 lbs.O. approved for refilling. See page 17. These tanks are not D.T. This refrigerant can be reclaimed later should 69788 need to be re-filled again with refrigerant. (See Empty Tank Alarm) NOTE: Do not attempt to charge a new refrigerant tank (blue tank with a single port valve). Press to interrupt the operation being performed. Press to launch the procedure or operation shown on the display. press STOP or RESET.charging. Press to move downward from one procedure or operation to another within a menu. The recovery operation is automatically interrupted. using a scale and a D. After the first alarm is cleared.T.O.CONTROLS AND CONTROL SYSTEM Refer to Figure 9. 24 lbs (10. At this time it will be necessary to bottle fill 69788 to approximately 12 to 15 lbs of refrigerant in order for the alarm to clear. ALARMS HIGH PRESSURE ALARM: FULL TANK ALARM: Beeper and LCD advise when the pressure of the fluid in the circuit reaches 290 psi (20 bar). charge one or more A/C systems before recovering any more refrigerant or. error state.oil discharge . Beeper and LCD advises when the tank is filled to more than 80% of maximum capacity.T. 20 characters ENGLISH �� �� �� �� FIG.T. Beeper and the LCD advise when the quantity of refrigerant fluid contained in the tank is too low. RESET: ↓: ↑: START: ENTER: Press to confirm the procedure or operation flashing on the LCD.T. when the total recovered amount of refrigerant reaches 132 lbs. Service Alarm: The first service alarm.O. The second service alarm. tank. 90 lbs minus 1.beeper will sound and the LCD will display ENTER FILTER CODE. and vacuum operations are performed in a sequence automatically. Replacing the dryer filters. Connect the hoses to the A/C system with the quick-connect couplings. If the units are in. using one of the two following procedures: 1. if the gas available is 9. then you will enter 9 8 0. Set the quantity of refrigerant to be charged. If the desired charge is 1. If the desired charge is 1 lb and 7 ounces. 69788 will interrupt the attempt to charge and notify the operator that there is insufficient refrigerant available. If the units are in. Allow both to run for about 5 to 10 minutes with the passenger compartment fan at full speed. NOTE: Should the automatic procedure be selected when the A/C system is empty. Connect the machine to the electrical supply and switch on. The minimum quantity of refrigerant is 4. the filters will need to be replaced (see page 16. When working with A/C systems with a single high-pressure (RED) coupling. 4. To type in.) Check that in the new oil container (Fig.80 lbs.80 lbs. then the display will have 4 digits separated by a colon and the units will be pounds. the “charging x: xx lb” message will flash. then you will enter 0 1 0 7. <VACUUM CHARGING XX MIN> lb <VACUUM CHARGING 20 MIN> lb X:XX X:XX →2→0→ After vacuum time has been confirmed. 7-N. page 8) is less than 6. (lb). oz(lb). 00:00lb. set the charging quantity at about 3 oz. (100 cc) of the oil recommended by the manufacturer of the vehicle A/C system. The cursor moves from the right to the left. use keys 0 to 9. the recovery and recycling. Set the quantity of refrigerant required for the A/C system to be charged.10 lbs is less than 4.50 lbs.90 lbs and the charge quantity is 1. then you will enter 1 7 5. Should this not be the case.80 lbs equals 4. On the menu press the down arrow until the selected line flashes. since it will be impossible to recover the residual refrigerant from the hoses after charging.50 lbs minus 1. Check that all the machine valves are closed. g (Kg). Vacuum Pump) INSUFFICIENT REFRIGERANT ALARM: Beeper and the LCD advise when the charging quantity set exceeds the amount of refrigerant available. At this time it will be necessary to bottle fill 69788 to approximately 12 to 15 lbs of refrigerant in order to perform a charge. 7. connect and open only the relative quick-connect coupling and hose. 00000g. If AC is not operational do not perform this step). 00. so 69788 will not charge and will let the operator know that there is insufficient refrigerant available. add oil as explained in the ROUTINE MAINTENANCE section (page 14.10 lbs.80 lbs equals 7. (100g) more than the required quantity.) Check the machine’s display to be sure there is at least 9 lbs (4. Start the vehicle engine and switch on the air conditioner (Only if vehicle’s AC is operational. 10 .70 lbs.08 kg) of refrigerant in the tank.) AUTOMATIC PROCEDURE In the automatic mode. bearing in mind that BLUE must be connected to the low-pressure side and RED to high pressure. Check that the oil level in used oil container (Fig. if the units are in. To simply confirm. If the gas available minus the charge quantity equals less than 4.7 oz. If the level is lower. then the display will have 5 digits and the units will be grams. oil discharge. Check that the high and low service valves on 69788 front panel are closed. in this manual it is enclosed in quotation marks. (200 cc. If the gas available is 5.75 lbs. For instance.50 lbs and the charge quantity is 1. The cursor moves from the left to the right. Open the quick-connect valves.) NOTE: It is good practice to change the Vacuum pump oil when the filters are being changed. then 9. (see page 15 & 16. fill the on-board machine tank from an external tank of appropriate refrigerant following the procedure described in the ROUTINE MAINTENANCE section (page 14. To deactivate the alarm. If the desired charge is 980g. 8-M. maximum 20 characters per line. Select the automatic procedure by pressing ENTER when “Automatic Procedure” flashes on the LCD. The cursor moves from right to the left. press ENTER.4 oz. The machine then goes on to automatic refrigerant charging when the start button is pressed.5 lbs. <AUTOMATIC ASSISTED NEXT Ref MENU avail X:XX lb PROCEDURE> <VACUUM CHARGING XX MIN> lb PROCEDURE X:XX →ENTER→ Type in the vacuum time or confirm the previous value. Check that the vacuum pump oil level indicator shows at least one-half full. then the display will have 4 digits separated by a decimal point and the units will be pounds. page 8) is set to 0. If the A/C system is equipped with a single quick-connect coupling for high or low pressure. the machine will begin with the vacuum phase.00lb.50 lbs so 69788 will perform the charge.70 lbs is greater than 4. Switch off the vehicle engine.50 lbs. page 8) there are at least 3. New oil can only be added after the vacuum pump has stopped. 7-I. For example. There will also be 10 dots along the bottom of the screen. The machine is equipped with a 4-line LCD display. PRELIMINARY OPERATIONS Check that the main switch (Fig. then 5. If you do not know the correct quantity. NOTE: Stopping the recovery phase before the oil is discharged may damage the recovery/recycle machine’s compressor. then press START ENGLISH 0→1→0→7→ENTER→ NOTE: When working with A/C systems with a single high-pressure (RED) coupling. purge the non condensable gases. The machine will be ready to enter the correct quantity of refrigerant. the machine will stop. The machine will automatically go on to running the vacuum phase for the preset time. NOTE: In most cases. Allow the unit to complete this procedure. The alarm will sound continuously and the display will show: AIR PURGE ref psi x:xx lb Recovery Tp: xx T:xx ˚F The Recovery/Recycle machine will automatically purge non-condensable gases (NCGS) if excess NCGS are detected at the end of recovery. During this phase.yz” refers to the amount of refrigerant for the vehicle selected. the machine will stop and automatically discharge the used oil extracted from the A/C system during the recovery phase. The display will now show the various models (for example. Upon completion of discharge. and if it’s necessary. which will be indicated on the LCD as “Recovery/Recycling”. recovery will automatically restart. the quantity of refrigerant being charged into the A/C system is given on a data plate inside the engine compartment of the vehicle. eliminating the chance of NCGS being charged to the AC system. set the charging quantity 3 oz. This model is equipped with refrigerant capacities stored in its database. emit a beep.VACUUM <CHARGING XX MIN XX:XX lb> Open high and low valves. Confirm by pressing the ENTER key. The oil discharge operation lasts 4 to 12 minutes depending on the ambient temperature. since in this case it will be impossible to recover the residual refrigerant from the hoses after charging. The following will appear on the display: VACUUM <FILLING 20 MIN lb> w:yz where “w. and display: OIL INJECTION Press Start to continue 11 . If any residual refrigerant is left in the A/C system. as indicated by an increase in pressure during the oil discharge phase. if the brand chosen was FORD): <COUGAR> ESCORT ESCORT FIESTA D Use the arrow keys (↓↑) to select the model required and press ENTER to confirm. the machine will check for the presence of air in the tank. Upon completion of the vacuum phase. consult the relevant manuals.19 lb or 85g) more than the required quantity. the LCD will display the quantity of refrigerant recovered. Upon completion of recovery. the following will appear on the display: <ALFA AUDI BMW CHRYSLER/JEEP ROMEO> Use the arrow keys (↓↑) to select the required vehicle brand and press ENTER to confirm. Press the ↓ key. Open the high and low service valves on the machine and press the START key to begin the refrigerant recovery/recycling phase. 2. The words “Recovery/Recycle” will flash while the oil is being discharged. (. ASSISTED PROCEDURE RECOVERY AND RECYCLING Connect the hoses to the A/C system with the quick-connect couplings. then press START. Press ENTER to confirm. Upon completion of the oil injection . with the A/C system still running. The unit is equipped with a tank heater to limit this occurrence. VACUUM Use the quick-connect couplings to connect the hoses to the A/C system. the LCD will display the quantity of refrigerant recovered. Open the high and low pressure valves of the machine and press START. the machine will check for the presence of air in the tank. open the NEW oil valve and add the needed quantity. If oil is needed. Switch off the vehicle engine. when the message “Vacuum xx min. Use only suitable oil with a separate oil injection device. recovery will automatically restart. Open the oil valve until the quantity equal to the quantity of oil previously extracted is transferred. as indicated by an increase in pressure during the oil discharge phase. The alarm will sound continuously and the display will show: AIR PURGE ref x: T: xx lb Recovery Tp: xx psi xx ˚F The recovery/recycle machine will automatically purge non-condensable gases (NCGS) if excess NCGS are detected at the end of recovery. NOTE: Charging may not run to completion due to pressure balance between the internal refrigerative storage tank and the A/C system. At this point the system will be at a steady state and it will be possible to check the high and low pressure valves on the relative pressure gauges. 10) Measure the quantity of oil extracted from the A/C system and check that the new oil container contains at least . If this occurs. the machine will display: END OF CHARGE Close HP and LP Press START to continue Close the high and low service valves. purge the non condensable gases. Then. Close the valve on the high-pressure (RED) quick-connect coupling. open the high and low pressure valves of the machine (if the A/C system is equipped with a single quick-connect coupling for high or low pressure. Select the assisted procedure by pressing ENTER when “Assisted Procedure” flashes on the LCD. Select the assisted procedure by pressing ENTER when “Assisted Procedure” flashes on the LCD. If the system is equipped with a single quick-connect coupling for high or low pressure. bearing in mind that BLUE must be connected to the low pressure side and RED to high pressure. open only the relative valve). 12 ATTENTION: Since the oil in the container will decrease in level. Open the high and low service valves on the machine and press the START key to begin the refrigerant recovery/recycling phase. open the high and low service valves to enable the A/C system to evacuate the refrigerant contained in the hoses. 69788 will pause and give the operator an opportunity to inject oil. Failure to close the valve will result in the refrigerant over pressurizing the NEW oil bottle and possibly causing the bottle to rupture.” flashes on the LCD. Upon completion of discharge.) With the A/C system in vacuum. start the vehicle and switch on the A/C system. Set the vacuum time only if different from that previously used. connect only the relative coupling and hose.At this point. NOTE: Using PAG oil or tracer in hybrid vehicles may damage the compressor. close the NEW oil valve and press START to go on to charging the quantity of refrigerant set previously. When the charging operation is complete. Only perform this step if the vehicle’s AC is operational. close both service valves and the valve on the low side coupling. the quantity must be calculated by difference. Then disconnect the low and high pressure coupling from the vehicle A/C system and switch off the engine. Start the vehicle engine and the A/C system and allow both to run for at least 3 minutes. The oil discharge operation lasts 4 to 12 minutes depending on the ambient temperature. Allow the unit to complete this procedure to reduce the risk of comebacks that can be caused by charging excess NCGS into an A/C system. close the high pressure valve (leaving the low-pressure side open). During this phase. Upon completion of recovery. connect only the relative hose. If the A/C system is equipped with a single quick-connect coupling for high or low pressure. Check that the high and low pressure valves are closed. Start the vehicle engine and the air conditioner and allow both to run for 5 to 10 minutes with the passenger compartment fan at full speed. Close the oil valve when reaching the desired oil level. the machine will stop and automatically discharge the used oil extracted from the A/C system during the recovery phase. When completed. The words “Recovery/Recycle” will flash while the oil is being discharged. If no oil is to be injected. ADDING NEW OIL (Fig. If any residual refrigerant is left in the A/C system. which will be indicated on the LCD as “Recovery/Recycling”. Select recovery and recycling by pressing ENTER when “Recovery/Recycling” flashes on the LCD. NOTE: Stopping the recovery phase before the oil is discharged may damage the recovery/recycle machine’s compressor.67 oz (20 cc. NOTE: It’s very important to remember to CLOSE the new oil valve before pressing the START button. Select the vacuum operation. and if it’s necessary. When the high and low side pressure is equal. bearing in mind that BLUE must be connected to the low-pressure side and RED to high pressure. then the display will have 5 digits and the units will be grams. if the brand chosen was FORD): <COUGAR> ESCORT ESCORT FIESTA D Use the arrow keys (↓↑) to move to the model required and press ENTER to confirm. confirm by pressing the enter key. 00000g. then you will enter 1 7 5. If the units are in. When “REF CHARGING XX:XX lb” flashes on the LCD: Set the quantity of refrigerant to be charged. you may go on to refrigerant fluid charging. (lb). use one of the two procedures below. 2. Press the down arrow to select REF CHARGING. Confirm by pressing the ENTER key. The cursor moves from the right to the left. oz(lb). ENGLISH ��������� ������������������� FIG. set the charging quantity 3 oz. For example. If the desired charge is 1. The display will now show the various models (for example.75 lbs. if the units are in. The following will appear on the display: VACUUM <FILLING 20 MIN lb> w:yz Where “w:yz” refers to the quantity for the vehicle selected.00lb. then the display will have 4 digits separated by a colon and the units will be pounds. NOTE: Using PAG oil or tracer in hybrid vehicles may damage the compressor. After setting the quantity.phase. since in this case it will be impossible to recover the residual refrigerant from the hoses after charging. 10 CHARGING THE A/C SYSTEM Press the UP or DOWN arrow to select the ASSISTED PROCEDURE and then press ENTER when the “Assisted Procedure” message flashes on the LCD.19 lb or 85 g) more than the required quantity. The machine will be ready to enter the correct quantity of refrigerant. (. NOTE: When working with A/C systems with a single high-pressure (RED) coupling. then you will enter 9 8 0. Press the ↓ key. If the units are in. 00. Use only suitable oil with a separate oil injection device. then you will enter 0 1 0 7. Open the high and low service valves on the machine and press the START key (in the case of an A/C system with a single high or low pressure 13 . If the desired charge is 1 lb and 7 ounces. If the desired charge is 980g. The cursor moves from the left to the right. The cursor moves from right to the left. This model is equipped with some refrigerant capacities stored in its database. the following will appear on the display: <ALFA AUDI BMW CHRYSLER/JEEP ROMEO> Use the arrow keys (↓↑) to select the required vehicle brand and press ENTER to confirm. 00:00lb. g(Kg). 1. then the display will have 4 digits separated by a decimal point and the units will be pounds. Manual Operation: Set the quantity of refrigerant for the A/C system to be charged. Then. ROUTINE MAINTENANCE FILLING THE MACHINE TANK This operation must be performed whenever the available refrigerant fluid in the tank is less than 9 lbs (4. connect the high pressure hose from the tank to the high pressure valve on the machine. Connect the tank adapter fitting (69788-332) to the R134a tank. If this occurs. The MAIN MENU will appear after a few seconds: AUTOMATIC ASSISTED <NEXT Ref PROCEDURE PROCEDURE MENU> X. close the valve on the high pressure quick connect coupling (leaving the low-pressure side open). Open the external tank valve. Use the HP hose to connect the external tank and press START Press START again: Follow the instructions on the screen. open only the relative valve on the machine). Obtain a tank of R134a. The unit is equipped with a tank heater to limit this occurrence. Switch the machine on. When the charging operation is complete. open the high and low service valves to enable the A/C system to evacuate the refrigerant contained in the hoses. the machine will display: END OF CHARGE Close HP and LP Press START to continue Close the high and low service valves.XX lb avail Select NEXT MENU: CALIBRATION DATA AND CONFIGURAT. NOTE: Charging may not run to completion due to pressure balance between the internal tank and the A/C system. If the external tank is not supplied with a liquid valve.8 kg) and must be performed when the “Empty Tank” alarm is displayed. 14 . ALARM SERVICE <TANK CHARGING> Select TANK CHARGING: TANK Set Min: Press CHARGING amount x Max: START xx xx lb lb Set the quantity of refrigerant and press START to confirm: Follow the instructions on the screen. close both service valves and the valve on the low side coupling. turn it upside down to obtain a higher delivery rate. with the A/C system still running. turn on the vehicle and switch on the A/C system. Then disconnect the low and high pressure coupling from the vehicle A/C system and switch off the engine. Start the vehicle engine and the A/C system and allow both to run for at least 3 minutes. Then. Recommended capacity is between 10 and 15 lbs. When the high and low side pressure is equal. Close the valve on the high-pressure (RED) quick-connect coupling. At this point the system will be at a steady state and it will be possible to check the high and low pressure valves on the relative pressure gauges. Open both the valve on the external tank and the high pressure valve on the machine. and press START. open HP valve.coupling. 1lb (≈500g).) Slowly add oil until oil level rises to the top of the oil level line.) 15 . Close the high pressure valve. The machine will stop automatically after having recovered the residual refrigerant from the hoses.) 5. � � ��� ��� ��� � � ��� ������ ��������������� ������������� � FIG.) 6.) 3) Unscrew the oil fill/muffler plug (Fig 11. use only the oil recommended by the manufacturer. Do not overfill with oil! (Fig 11-4.) Replace the oil fill/muffler plug (Fig 11.(NEW MACHINE) This vacuum pump has been tested at the factory and shipped with only trace amounts of oil.2.) D) Attach the filling hose (Fig.) Re-install the rear cover (6 screws. 2) Remove the rear cover (6 screws. 11-6.2. VACUUM PUMP Perform the operations listed below on a routine basis in order to ensure the best operation of the vacuum pump: When filling or replacing the pump oil. OIL MUST BE ADDED BEFORE OPERATING! Failure to add oil will damage the cartridge and void warranty.) 7. 11 OIL FILL .) 1) Disconnect the machine from the electrical supply.1lb (≈500g) is reached.) 4) Oil Bottle: A) Remove oil bottle cap B) Remove the silver foil C) Attach the filling top (be sure to remove the red cap) (Fig.Press START again: TANK 0 LB xx xx PSI PSI CHARGING ENGLISH ACP TP The machine will now fill the machine tank with the preset quantity ±1. When the quantity minus 1. NOTE: Make sure the oil drain valve located below the front casing is closed before attempting to add oil (Fig 11-3. 11-5. the machine will stop and display: TANK CHARGING Close external tank and Press Start Close the tank valve and press START. Disconnect the external tank. obtain an empty 16 oz. To input a letter. 11. 16) Connect the machine to the electrical supply and turn the machine on.) 6) Close the drain plug (Fig. 12-3] should be open). continue to press the same number with the corresponding letter until the desired letter appears.) 4) Close both of the valves on top of tank. you will need to FIG.) 9) Replace the rear plastic cover on the machine (6 screws. Technical Service at 888-825-6989. 9) Using Assisted Procedure.) NOTE: When changing the vacuum pump oil. � 8) Put in the filter code. 12-1) under the filter (Fig. or 4) Whenever the oil changes color due to absorption of moisture. OIL CHANGE The vacuum pump oil must be replaced: 1) Every 120 working hours. � 3) Remove the rear plastic cover from the machine (6 screws. To obtain a filter code. 12-4.CHECKING OIL LEVEL The oil level in the sight glass should be between the max and min line (Fig 11-4.) 7) Pour in new oil through the fill hole until the level rises to the midpoint on the indicators (Fig. 12-3) under the filter (Fig. 12) Disconnect the low pressure quick-connect coupling from the connector (Fig. 12 use the down arrow key to move the cursor to the next character. no filter code will be needed to continue operating 69788. Before changing the filters. LOCK OUT: If you are changing the filters because of the Second Service alarm (see page 9) and has locked out 69788. When changing the filters you will need a filter code. dispose of used oil as per federal. the filter code will be needed to re-set 69788. Replace the filters only with Mastercool part numbers: 69788-FLTRPK. 11-4. 12-4.) 5) Allow all the oil to run out into a disposal container (drain clearance is less than 3.) 8) Replace the oil fill/muffler plug (Fig. IMPORTANT: The filter replacement must be performed as quickly as possible in order to avoid possible contamination by moisture in the ambient air. press the ENTER key.) 3) Unscrew the oil fill/muffler plug (Fig 11. 11-2. Only when the machine reaches the pre-programmed recovery quantity of 132 lbs will it lock out. 10) When zero pressure is reached. 11) Disconnect the machine from the electrical supply. proceed as described below (refer to Fig.3. Once the machine is locked out.95 inches. 13) Replace the filters. 12-5). then a filter code will be needed to re-set 69788. 12): 1) Disconnect the machine from the electrical supply. start a recovery operation (NOTE: the valve under the low pressure filter [Fig.) If oil level falls below the MIN line add oil per oil fill instructions. 12-4) and the valve (Fig.) 6) Connect the low pressure quick-connect coupling to the male connector (Fig. 15) Open both valves on top of the tank. or 3) At the beginning or end of every season. 14) Open the valve (Fig. 12-3) under the filter (Fig. 11-3. 5) Close the valve (Fig. 12-5) and press STOP or RESET. NO LOCK OUT: If the filters are being changed at an unscheduled time. local and state regulations. 12-1) under the filter (Fig. Before beginning the oil change procedure. 12-2) under the filter (Fig. � � 16 . Once the entire code is showing on the screen. or 2) When the filter/dryers are replaced. (1 pint) or larger container in which to collect the used oil. 12-4).2. REPLACING THE DRYER FILTERS Replace the filters when the machine alerts you.) 7) Connect the machine to the electrical supply and turn the machine on. � 2) Wear protective gloves and glasses. 2) Remove the rear cover (6 screws.) 4) Unscrew the drain plug (Fig. immediately close the valve (Fig. (Only if locked out) To put in the filter code. 12-2) under the filter (Fig. please call Mastercool Inc. 1) Disconnect the machine from the electrical supply. call Mastercool Inc. Technical Service at 888-825-6989 to get the filter code. (See LOCK OUT) To change the filters. (Leave the rear cover off at this time) 17) Bottle fill about 1 lb (~500g) of refrigerant to charge the machine circuit. 0 216. local and state regulations.3 77.8 ˚F 106 104 102 100 98 96 94 92 90 PSI 137.3 166.5 142.3 146.9 193. � � EMPTYING THE USED OIL CONTAINER This operation must be performed whenever the oil level exceeds 6.2 74.1 161.7 60.1 33. Re-tighten if necessary.1 Note: The units of negative pressure values are inHG 17 .7 14. Refer to the Pressure/Temperature Chart (P/T Chart) Fig. ENGLISH FILLING THE NEW OIL CONTAINER It is good practice to fill the oil container whenever the oil level falls below 3. This is the pressure that should be in the tank. Any pressure above that value is NGC.5 ˚F 124 122 120 118 116 114 112 110 108 PSI 182.5 27. � � � FIG.3 ˚F 34 32 30 28 26 24 22 20 18 PSI 29. Screw the container back in place while holding the cap in place.3 120.2 176.8 300. The equipment necessary for scale re-calibration is not supplied with 69788.2 86.1 108. PRESSURE/TEMPERATURE CHART R134a ˚F 200 190 180 170 160 150 148 146 144 Fig. 1.2 104. Screw the cap back on and.5 43.7 oz (200 cc.3 65.7 204.4 17.8 210. use an electronic leak detector to check the seal on the connections that were opened to replace the filters.28g.0 249.9 434. lifting the quick-connect coupling as above.1 187.0 256.5 55.1 93.4 ˚F 142 140 138 136 134 132 130 128 126 PSI 235.18) While the machine is recovering.0 35.7 45. Empty the used oil into a suitable container for used oils.8 83.8 26.5 124.3 41.1oz depending on what units the machine is set at.1 151. The following screen will be displayed: AIR PURGE START psi T: xx.2 242.3 50. Always refer to the information provided by the A/C system manufacturer for oil specifications (oil is not supplied. 14 and determine what pressure matches the temperature showing on the screen. Hang the 500g test weight that was supplied with the machine from the hook under the scale.2 ˚F 70 68 66 64 62 60 58 56 54 PSI 71. 13 PURGING NON-CONDENSABLE GASES If 69788 should become loaded with excessive tank pressure due to the accumulation of NCG (Non-Condensable Gases) it will be necessary that the operator purge the NCG manually.4 223.06lb or 1lb 2oz +/.9 21. (6 screws) 20) The machine is now ready for normal use. The operator will need to start and stop the manual purge.0 ˚F 16 14 12 PSI 15. scroll down with the arrow. The scale re-calibration should be done by a qualified Service Technician.7 97.1 57.4 19. 19) Turn the machine off and replace the rear plastic cover on the machine.5 22.1 39. 14 PSI 488.6 90. (Dispose of used oil as per your federal.2 68.6 171..1 ˚F 52 50 48 46 44 42 40 38 36 PSI 47.0 52. select AIR PURGE.4 oz (100 cc) in order to guarantee that there will be sufficient oil for � topping off during successive operations. (Fig 13-7) The “REF AVAILABLE” should go up by 500g +/.) Procedure: Remove the container from its holder.0 263.4 13.4 ˚F 88 86 84 82 80 78 76 74 72 PSI 100.x ˚F PRESS Tp: xx Note the Tp (Tank Pressure) and T (Temperature). replace the container � in its holder.1 24.2 31.9 128. Carefully replace the container into its holder. Select NEXT MENU.6 340. If the results of the test are not within these specifications.1 112. Unscrew the container while holding the cap in place. it is recommended that the scale be re-calibrated.5 62.9 385.9 18.7 198.3 132.) CHECKING THE SCALE RESPONSE Turn the unit on and note the “REF AVAILABLE” reading.10lb +/.1 116.8 229. Unscrew the cap and fill the container with the correct quantity of oil of suitable type and grade.5 80.) Lift the quick-connect coupling near the top of the container and remove the container complete with cap.1 156.1 37. Confirm a language by pressing ENTER. Use the ARROW keys to scroll the available languages. Press RESET for MAIN MENU.XX lb avail Select NEXT MENU: 18 . The MAIN MENU will appear after a few seconds: AUTOMATIC ASSISTED <NEXT Ref PROCEDURE PROCEDURE MENU> X. UNITS OF MEASUREMENT Switch the machine on.. SETTINGS LANGUAGE Switch the machine on. The MAIN MENU will appear after a few seconds: AUTOMATIC ASSISTED <NEXT Ref PROCEDURE PROCEDURE MENU> X. For example. NOTE: Purging to a pressure lower than what is determined from the P/T chart will result in a large loss of refrigerant. The P/T chart say’s that the pressure at 80˚F should be 86.XX lb avail Select NEXT MENU.> SERVICE TANK ALARM CHARGING Select DATA AND CONFIGURAT.8 PSI. That means that there is approximately 53 PSI of NCG. Press STOP when the pressure is approximately 5 to 10 PSI higher than what the P/T chart say’s it should be for the temperature showing on the screen. Press ENTER: CALIBRATION <DATA AND CONFIGURAT. stopping the purge at 90-95 PSI will be sufficient enough for 69788 to operate properly while not releasing too much refrigerant. In this case.Press START: the machine will begin to discharge the air and the pressure value on the screen will gradually decrees. The machine will reset and a few seconds later the MAIN MENU will appear in the chosen language. if Tp is 140 PSI and the T is 80 degree F. Press ENTER: DATA <CONFIGURATION> SERVICES PREVIOUS MENU Select CONFIGURATION: <LANGUAGE> MEASURE PREVIOUS UNITS MENU Select LANGUAGE: ENGLISH ITALIANO FRANCAIS ESPANOL <- NOTE: The current language is indicated by the symbol “<-“. It’s normal and unavoidable that a small amount of refrigerant is lost while purging. > SERVICE TANK ALARM ENGLISH CHARGING Select DATA AND CONFIGURAT: DATA <CONFIGURATION> SERVICES PREVIOUS MENU Select CONFIGURATION: LANGUAGE <MEASURE PREVIOUS UNITS> MENU Select MEASURE UNITS: WEIGHT PRESSURE TEMPERATURE EXIT oz(lb) psi ˚F WEIGHT Select WEIGHT: WEIGHT PRESSURE TEMPERATURE EXIT oz(lb) psi ˚F Press ENTER to change from g (kg).CALIBRATION <DATA AND CONFIGURAT. 19 . oz (lb) or lb WEIGHT PRESSURE TEMPERATURE EXIT oz(lb) psi ˚F Select another parameter or EXIT to go to the previous screen. PRESSURE Select PRESSURE: WEIGHT PRESSURE TEMPERATURE EXIT oz(lb) psi ˚F Press ENTER to change from bar to psi or from psi to bar. WEIGHT PRESSURE TEMPERATURE EXIT oz(lb) psi ˚F Select another parameter or EXIT to go to the previous screen. ACp: pressure in the external air conditioning system. The MAIN MENU will appear after a few seconds: AUTOMATIC ASSISTED <NEXT Ref PROCEDURE PROCEDURE MENU> X. 20 . To use the password feature.xx xx lb ˚F Tp: xx psi ACp: xx psi NOTE: TP: xx psi will be flashing .Tp: pressure of refrigerant tank. . DATA This menu shows all the data read by the machine. PASSWORD PROTECTION A password can be used to prevent the machine from being used.> SERVICE TANK ALARM CHARGING Select DATA AND CONFIGURAT. it will be needed every time the operator makes an attempt to activate any command from the MAIN screen. Switch the machine on. The following screen will be displayed: Ref Tank avail temp. . Once a password is activated. .: <DATA> CONFIGURATION SERVICES PREVIOUS MENU Select DATA.: temperature of the refrigerant storage tank.: quantity of refrigerant available in the storage tank. xx.Tank temp.Ref avail.TEMPERATURE Select TEMPERATURE: WEIGHT PRESSURE TEMPERATURE EXIT oz(lb) psi ˚F Press ENTER to change from °C to °F or from °F to °C.XX lb avail Select NEXT MENU: CALIBRATION <DATA AND CONFIGURAT. WEIGHT PRESSURE TEMPERATURE EXIT oz(lb) psi ˚F Select another parameter or EXIT to go to the previous screen. .: DATA CONFIGURATION <SERVICES> PREVIOUS MENU Select SERVICES: <PASSWORD> COUNTERS Select PASSWORD: . Scroll down with the (↓) DOWN arrow key until the vehicle brands in the DBA appear: ROMEO> CHRYSLER/JEEP Press the (↑) UP arrow key: TOYOTA VOLKSWAGEN VOLVO <USER DEFINED> Select the USER DEFINED option: <ABCD EFGH> 21 .AUTOMATIC ASSISTED <NEXT Ref PROCEDURE PROCEDURE MENU> X. Put in your own 4 digit password and press enter.. SYSTEM FLUSHING (OPTIONAL) See instructions provided with the flushing kit CUSTOMIZING THE DBA (DATABASE ADVANCED) <ALFA AUDI BMW Select ASSISTED PROCEDURE..> SERVICE TANK ALARM CHARGING Select DATA AND CONFIGURAT.XX lb ENGLISH avail Select NEXT MENU: CALIBRATION <DATA AND CONFIGURAT. scroll with the (↑↓) arrow keys to the desired vehicle model and press “0” (ZERO). MODEL XXXX QUANTITY: Type in the vehicle model on the keyboard.. press START.... DELETION To delete custom data fields... press ENTER to confirm. scroll with the (↑↓) arrow keys to the desired vehicle model...27 multiply by 0. The following screen will be displayed: MODEL NAME: .. NOTE: Refrigerant quantity is in grams. CONVERSION CHART Ounces (oz) to pounds (lbs): Pounds (lbs) to ounces (oz): Ounces (oz) to grams (g): Grams (g) to ounces (oz): divide by 16 multiply by 16 multiply by 28.....0284 22 .205 Kilograms (kg) to pounds (lbs): multiply by 2. Use the down arrow key to move the cursor to the next character. DATABASE UPGRADE Database upgrades are available. The database data must nevertheless be considered purely indicative.. press ENTER to confirm.. Type in the corresponding refrigerant quantity. Call 973-252-9119 and ask for details.HIJK MNOP ???? ???? DATA ENTRY To enter customized data. USE To use the customized data. the manufacturer declines any and all responsibility for incorrect data. An alarm signal will sound and the following screen will be displayed....4 divide by 28.4 Pounds (lbs) to kilograms (kg): divide by 2.205 Kilograms (kg) to ounces (oz): Ounces (oz) to kilograms (kg): multiply by 35. VEHICLE XXXX G NAME DELETE? START: YES STOP: NO Press START to delete the vehicle or STOP to exit without deleting the vehicle. press ENTER to confirm.. NOTE CONCERNING THE DATABASE: We have taken all due care in gathering and entering the information contained in the database... 23 ENGLISH . If you have difficulty with a procedure please call Mastercool’s Technical Service at 973-252-9119 24 69788-INST-0811 .